A Stone Worktop System, A Composite Stone Board, and a Method of Manufacturing a Composite Stone Board
A stone worktop system is disclosed and particularly, but not exclusively, a composite stone worktop system for use by an end user to assemble. In addition, a method of manufacturing a composite stone worktop, a clamping system for a stone worktop system and a clipping system for stone worktops is disclosed.
The present invention relates to a stone worktop system and particularly, but not exclusively, a composite stone worktop system for use by an end user to assemble. In addition, a composite stone board, a method of manufacturing a composite stone board, a clamping means for worktops, a clipping means for worktops and a backing board for a worktop is disclosed.
BACKGROUND ARTComposite stone worktops are an increasingly popular solution for residential kitchens and other situations in which a hard wearing yet aesthetic surface is required. Composite stone worktops are currently available, mostly, in a bespoke form, where dimensions for the particular installation are provided to a stone mason to manufacture the worktop. This means that, despite the cost of composite stone being relatively inexpensive, the labour required to manufacture the worktops to a satisfactory standard in a bespoke manner means that the overall cost is relatively high. Some retailers have provided ‘do-it-yourself’ composite stone worktops previously but the product was not user friendly, as significant modification was required, which resulted in a poor finish and, ultimately, no market desire for the product.
DISCLOSURE OF INVENTION Disclosure SummaryAccording to a first aspect of the present invention there is provided a stone worktop system including a stone worktop fabricated to receive a pre-fabricated backing board according to as described in relation to the second aspect of the present invention.
Preferably, the system includes clamping means as describe in relation to the third aspect of the present invention.
Preferably, the system includes clipping means as described in relation to the fourth aspect of the present invention.
Preferably, the stone worktop includes at least one recess for receiving a waterfall end and the system further including at least one waterfall, the or each waterfall end having a protrusion corresponding to the recess, such that upon insertion of the protrusion into the recess, the stone worktop and waterfall end are substantially self-supporting.
According to a second aspect of the present invention there is provided a composite stone worktop including a composite stone board having a backing board formed therein. Preferably, the backing board is integrally formed with the composite stone worktop. Preferably, the backing board is made of plastic, wood, metal, carbon fibre, or a combination of these materials. Preferably, the backing board has a plurality of recesses and the stone board has corresponding protrusions. Alternatively, the recesses in the backing board are capable of receiving alternative strengthening materials, such as stone, wood, metal, carbon fibre or plastic.
Preferably, the composite stone worktop forms part of a ‘waterfall’ kitchen feature. A waterfall, in terms of stone worktops, is a stone worktop which is supported at two ends with corresponding stone ‘slab’ legs, the effect being that the worktop appears to continue to the floor (or waterfalls down from the worktop to the floor). Preferably, the composite stone worktop includes stone leg receiving recesses and the stone legs have corresponding protrusions, such that, when the stone leg is abutted to the worktop, an outer face of the stone leg is substantially in the same plane as the corresponding end of the worktop.
Preferably, the composite stone worktop is manufactured according to the first aspect of the present invention.
According to a third aspect of the present invention there is provided a clamping means for two worktops including: a first anchoring means attachable to a first worktop and a second anchoring means attachable to a second worktop, an inner screw and an outer screw barrel, the inner screw attachable to the first anchoring means and the outer screw barrel attachable to the second anchoring means, wherein, the inner screw and outer screw barrel are capable of being screwed together whilst remaining attached to the respective anchoring means.
In the context of the clamping means, a worktop refers to any type of worktop surface, such as laminate, wood, stone or composite stone with or without a backing board. In the context of the stone worktop system according to the first aspect of the present invention, the worktop includes the stone and backing board and a reference to worktop can mean the stone, the backing board or both.
Preferably, one of the inner screw or outer screw barrel are prevented from rotation by the first or second anchoring means. That is, if the inner screw is prevented from rotation by the first anchoring means, then the outer screw barrel is capable of rotation and, if the outer screw barrel is prevented from rotation by the second anchoring means, the first inner screw is capable of rotation.
Preferably, the first anchoring means includes a first anchor barrel having a first passage for a first anchor attachment means, and a second passage for the inner screw. Preferably, the second anchoring means includes a first anchor barrel having a first passage for a second anchor attachment means, and a second passage for the inner screw. Preferably, the first and second anchor attachment means are screws.
Preferably, the inner screw has an end stop which is capable of engaging with the first anchoring means such that the inner screw is prevented from rotating. Alternatively, the outer screw barrel has an end stop capable of engaging with the second anchoring means such that the outer screw barrel is prevented from rotating.
In an alternative embodiment of the clamping means, the first anchoring means is insertable into a recess in the first worktop and the inner screw is insertable into a passage in the first worktop which connects with the recess, and the second anchoring means is insertable into a recess of the second worktop and the outer screw barrel is insertable into a passage in the second worktop which connects with the recess.
In a further alternative embodiment of the clamping means, the inner screw comprises a first rotation means at one end and the outer screw barrel is fixedly attached to the second anchoring means such that relative rotation of the screw barrel and second anchoring means is prevented. Preferably, the outer screw barrel is a nut. Preferably, the first anchoring means include two faces at right angles to one another, one face having a passage which allows the inner screw to pass through but not the first rotation means attached to one end of the inner screw. The other face having a passage with a second rotation means, the second rotation means capable of engaging with the first rotation means to such that rotation of the second rotation means also rotates the first rotation means. Preferably, the first and second rotation means are bevel gears. Alternatively, the first and second rotation means are a worm and worm gear respectively (or vice versa).
In a further alternative embodiment of the clamping means, the inner screw comprises an end stop at one end and the outer screw barrel is a first rotation means. In this embodiment, the first anchoring means includes a passage that the inner screw passes through except of the end stop. The inner screw is free to rotate in the passage. The second anchoring means includes two faces at right angles to one another, one face having a passage which allows the inner screw to pass through and engage with the first rotation means. The first rotation means held to the second anchoring means due to this engagement. Rotation of the first rotation means screws the inner screw through the first rotation means. The other face of the second anchoring means having a passage with a second rotation means, the second rotation means capable of engaging with the first rotation means such that rotation of the second rotation means also rotates the first rotation means. Preferably, the first and second rotation means are bevel gears. Alternatively, the first and second rotation means are a worm and worm gear respectively (or vice versa).
According to a fourth aspect of the present invention there is provided a worktop accessory clipping system for attaching accessories to worktops including a clip having an accessory attachment means and a resiliently deformable portion, the resiliently deformable portion extending from the accessory attachment means and capable of being deformed when attached to an accessory and being inserted through a worktop and, at a pre-determined thickness, or range of thicknesses, corresponding to the thickness, or range of thicknesses of the worktop, resiliently extending beyond the further surface of the worktop to grip the accessory to the worktop. Preferably, the clip is made of spring steel.
According to a fourth aspect of the present invention there is provided a backing board for a stone worktop including a plurality of recesses on one side of the backing board for receiving strengthening material.
Preferably, the recesses are configured to receive composite stone as the strengthening material and, further preferably, the recesses are configured to receive a composite stone slurry prior to the slurry hardening, and becoming the strengthening material.
In one embodiment, the recesses are configured to receive the strengthening material on a side opposite to where the stone worktop is received. Alternatively, the recesses are configures to received the strengthening material on the same side in which the stone worktop is received.
Preferably, the recesses are formed diagonally with respect to edges of the backing board and, further preferably, the diagonal recesses are configured, if the backing board is placed next to another substantially identical backing board, to provide continuous recesses from the backing board to the identical backing board. Preferably, the diagonal recesses include a set of a plurality of diagonal recesses parallel to one another in the same direction and there are at least two sets of the plurality of parallel diagonal recesses.
Preferably, the backing board is of generally rectangular shape such that the length of the longest side of the backing board is twice that of the shortest and the recesses are formed between the corners of the backing board and between the mid-points of each side and the respective sides immediate perpendicular neighbour.
In other words, the backing board includes a plurality of diagonal channels. The plurality of diagonal channels arranged such that placing a second backing board alongside a first, the diagonal channels of the first backing board are capable of corresponding to those of the second backing board. In this context, ‘diagonal’ refers to an arrangement in which the channels are not orthogonal to the edges of the backing board. Preferably, one or more diagonal channels originate in a corner of a rectangular backing board and continue to the opposite corner. Further preferably, one or more diagonal channels originate from a mid-point of one edge of a rectangular board and continue to a mid-point of an orthogonal edge of the rectangular board.
Preferably, the backing board includes a plurality of clamping recesses at edges of the board for receiving clamping means for clamping two or more boards together or for clamping to another object. Preferably, the clamping recesses are suitable for receiving the clamping means of the third aspect of the present invention.
Preferably, the backing board includes a plurality of clipping recesses for receiving clips which can then attach the board to other objects. Preferably, the clipping recesses are suitable for receiving the clipping means of the fourth aspect of the present invention.
According to a sixth aspect of the present invention, there is provided a method of manufacturing a composite stone board including: providing a mixture of stone particles and a binder providing a mould wherein the mixture is deposited on the mould and subsequently hardened to provide the composite stone board.
Preferably, the mould is a backing board, the backing board providing support for the composite stone board.
Alternatively, the method further comprises removing the composite stone board from the mould and placing the composite stone board on a backing board.
Preferred embodiments of the invention will now be described, by way on non-limiting example only, with reference to the accompanying drawings, in which:
Stone worktops and, particularly, composite stone worktops, as mentioned above, are currently a popular solution for the work surfaces of residential kitchens, as well as other situations in which a hard wearing, yet aesthetic, surface is required. Composite stone is particularly desirable because it is lower cost and because it can be cut or prepared as a relatively thin layer, for example, composite stone, according to one aspect of the invention, can be produced between 2 mm and 20 mm, and then adhered or veneered to a backing board. Preferably, due to the strength provided by the backing board according to one aspect of the invention, the composite stone thickness is minimised, and preferably, the thickness of the board is between 2 mm and 9 mm. Standard kitchen worktops are 30 mm deep; however, there is a trend to use thicker worktops, such as 40 mm. By reducing the thickness of the stone or composite stone used, a lighter and more cost effective product can be produced. It is possible to veneer natural stone to a backing board which, whilst more expensive than composite stone, has similar weight and cost advantages over a full stone thickness worktop.
Composite stone is a man-made product which is produced by making a slurry of crushed stones and adhesives and/or acrylic. The slurry is poured and pressed into slabs to create a product for use in worktops.
Currently, if a new kitchen worktop surface of stone is required, such as worktop 10 shown in
A stone mason will then take the kitchen installers measurements and template board and construct a backing board, made out of wood or a wood based product, and cut the stone to fit the measurements and template board and then adhere the stone to the backing board. During this process, the stone mason will construct an edge to the stone, which hides the fact that the worktop is not completely stone, but contains a lighter core backing board. This process if the same no matter whether natural stone or composite stone is used.
Whilst the above known method of constructing a kitchen stone worktop, or any other stone worktop, provides a useful end product, a large amount of time is required by the kitchen installer and stone mason to produce the required worktops. In particular, a template board, a backing board and the stone requires to be constructed and finished. This results in a very expensive finish, when compared with polyester/acrylic products, such as Laminex®, or wood based products, such as fibreboard/chipboard laminates.
Moreover, it is relatively straight forward for a kitchen installer, whether professional or a do-it-yourself enthusiast, to install a worktop made from polyester/acrylic or fibreboard/chipboard, as the products do not need to be specially manufactured and are easy to join together.
Referring now to
In an alternative embodiment, as shown in
The stone worktop described in relation to of
The backing board 34, and any other backing board discussed herein is, preferably, made out of plastics, making it more resistant to breaking down, especially due to water ingress, and giving longevity to the product. However, it can also be made of other appropriate materials, including wood or metal based products, or a combination of these.
To enable construction of the worktop 30, when it is made our of composite stone, the composite stone slurry, which is a mix of crushed stones and adhesives and/or acrylic, known as a binder, is poured onto a mould which matches the shape of the backing board, or is poured onto the backing board itself before being finished in a known manner of composite stone boards. Therefore, a composite stone board can be produced with an integral backing board. Alternatively, the mould is removed after the composite stone board has been produced and a backing board is subsequently attached, by, for example, adhesives.
It is also possible to create edges which hide the backing board automatically during this process by compacting the edges into the mould or using a mould which includes the provision of edges. The edges can then be finished by either cutting and polishing or just polishing, as the main surface of a composite stone board is typically finished.
Having the backing board and the stone integrally produced or combined at this stage also means less composite material is used to create a composite stone worktop, thus further reducing the cost of making the bench tops. This is particularly due to the waste stone produced when a stone mason is required to produce a custom worktop.
Referring now to
Referring now to
Furthermore, this particular embodiment of the board 1200 is a rectangular shape which may be separated at a mid-point of the longer side to form two smaller boards of a square shape, allowing additional flexibility. Alternatively, a board of a design corresponding to one half of the board 1200 (separated along the mid-point of the longer side) may be manufactured separately.
The board 1200 also includes clamping points 1212. These clamping points 1212 allow boards which have been abutted together, with or without being attached to corresponding stone, to be fixed from movement using a clamping means. Importantly, the clamping points are arranged such that, when boards 1200 are attached to corresponding stone, abutment and placement of the stone can be carried out easily and quickly.
In use, the recesses are filled with strengthening materials before being adhered to a natural or composite stone worktop. In this embodiment, the first side, as shown in
Whilst the backboards disclosed herein are, in general, described for use with composite stone worktops, it is also possible to use these backboards with stone which is not created in a composite manner, such as quarried stone. In a similar manner, the overall weight of stone worktop can be reduced.
Referring now to
A method of joining the side panels 60 and 61 is discussed below. However, these panel enable a number of designer features in kitchen installations including, for example, ‘waterfall’ joins, where the worktop continues from horizontal to vertical, usually all the way down to the ground and with a seamless join.
Now referring to
Backing board 70 requires to be affixed to a vertical supporting structure 72. In practice, the structure 72 can be a kitchen cabinet, wall or other suitable structure. To enable the backing board 70, and, therefore, the corresponding worktop, to be easily affixed, a recess 74 is provided in the backing board 70 into which a clip 76 can be temporarily or permanently seated. The clip 76 has an extending portion 78 which can receive a screw, or other attachment means, for fixing to the structure 72.
The clip 76 has a lip 79 which prevent lateral movement and, therefore, prevents the worktop from separating from the structure 72.
Backing board 71 is also affixed to the structure 72 and has a recess 74. An alternative clip 75 is shown, which still has an extending portion 78 for securing the clip to the structure 72. The clip 75 does not, however, have a lip preventing lateral movement. In this case, clip 75 can either allow lateral movement, or be permanently fixed into the backing board 71, and, therefore, prevent lateral movement.
Referring now to
Horizontal worktop 802 has a 45° face 804 at one end, a recess 806 a predetermined distance from the face 804 and a passage 808 between the recess 806 and face 804. Similarly, the vertical side panel has a 45° face 810, recess 812 and passage 814 between the face 810 and passage 814.
The passages 808 and 814 are arranged such that, if they meet substantially exactly, the face 810 and face 804 also meet substantially exactly, creating a smooth join between the horizontal worktop 802 and the vertical worktop 804. To enable the passages to meet exactly a fixing means 816 is provided.
For clarity, fixing means 816 is only fully labelled in
Fixing means 816 includes a first end stop 818, inner screw 820, outer screw barrel 822, second end stop 824, universal joint 826 and actuating bar 828.
In use, inner screw 820 is inserted into passage 814 from the face 810 and first end stop 818 is inserted into recess 812. Inner screw 820 is then engaged onto first end stop 818. The engagement between the inner screw 820 and the first end stop 818 is such that inner screw 820 is not free to rotate relative to the end stop 818. Moreover, the end stop 818 is, at least, prevented from exiting from the end of the inner screw 820. Furthermore, the end stop 818 is also prevented from rotating, preferably due to a combination of the shape of the end stop 818 and the shape of the recess 812.
Outer screw barrel is inserted into passage 808 from recess 806 with the second end stop 824 already in place. The inner screw 820 is inserted into the outer screw barrel 822 and the actuating bar 828 is rotated, which, due to universal joint 826, rotates the outer screw barrel 822. As such, the outer screw barrel 822 is screwed onto the inner screw 820. The two passages 814 and 808 are sized to match the outer screw barrel 822 such that, when screwed together, the two passages 814 and 808 meet up substantially exactly, as shown in
The fixing means 816, especially due to the universal joint 826, may be quickly screwed together using a power tool. Whether a power tool is used or not, the fixing means 816 is accessible vertically, so that access is easy and to increase the speed to tightening. In this case the actuating bar 828 has an end capable of being rotated by a suitable matching head on the power tool. For example, the actuating bar 828 can have a recess slot for accepting a corresponding flat screwdriver end or the actuating bar 828 can have a hexagonal end over which a standard socket. Having a fixing mechanism operable by a power tool is particularly advantageous in the field of stone worktops, as the stone worktops are heavier than standard worktops and, therefore, if manual fixings are used, additional persons are required to install. A fixing mechanism operated by a power tool allows for a quick install and allows for a person to operate the fixing mechanism with one hand allowing them to hold or manoeuvre the composite stone worktops being fixed together. Fixing means, such as described above reduces the amount of labour required to join the worktops together.
In addition, using a fixing means, such as that described in relation to
Although a universal joint 826 is shown for turning the outer screw barrel 822, it is possible to use alternative means of driving the outer screw barrel. For example, the screw barrel may have a hexagonal nut end and the recess may be large enough to allow a spanner or socket to be inserted to turn the barrel. Or, it may be possible to connect a flexible drive means, such as a spring steel gear.
An alternative means of fixing a worktop and side panel together is shown in
A further alternative means of means of fixing a worktop and side panel together is shown in
However, fixing means 1000 also has a first anchor barrel 1014 and first anchor screw 1016 as well as a second anchor barrel 1018 and second anchor screw 1020. The inner screw 1002 passes through the first anchor barrel 1014 and first end stop 1004 engages with first anchor barrel 1014. Similarly, the outer screw barrel 1006 passes through the second anchor barrel 1018 and second end stop 1008 engages with the second anchor barrel (although it allows the barrel to rotate).
In use, the first anchor screw 1016 is screwed into a predetermined point in the backing board of a composite stone worktop as described above, and the second anchor screw is screwed into a predetermined point on another composite stone worktop. When the outer screw barrel 1006 and inner screw 1002 are engaged and screwed together, the two composite stone worktops are drawn together.
Preferably, the predetermined points for the first and second anchor screws 1016 and 1020 are pre-formed in the respective backing boards of the worktops, so that accuracy is ensured.
Referring now to
The clamping means 1300 includes a first anchoring means 1302, in the form of a flat member 1302 and a second anchoring means 1304, in the form of an L-shaped member 1304. An inner screw 1306 is arranged to pass through respective passages in the flat member 1302 and L-shaped member 1304. A first end 1308 of the inner screw 1306, which passes through a passage in the flat member 1302, has a screw thread for accepting a nut 1310, the nut being an outer screw barrel in this embodiment. The nut 1310 can be fixed to the flat member 1302, so that it doesn't rotate, or it can be left so that it is free to rotate. If it is left free to rotate, the nut 1310 can either be held by a spanner, or other similar tool, or friction against the flat member 1302 can be sufficient to prevent the nut 1310 from rotating when the inner screw 1306 is rotating. A second end 1312 of the inner screw 1306, which passes through a passage in a first face 1314 of the L-shaped member 1304, is fixedly connected to a first gear 1316. The L-shaped member 1304, on a second face 1316, has a second passage through which a shaft 1318 passes through. On one end of the shaft 1318 is a second gear 1320 and on the other end of the shaft is a hexagonal drive 1322. The first gear 1316 and second gear 1320 are engageable such that rotation of one gear rotates the other.
Referring now to
The clamping means 1400 includes a first anchoring means 1402, in the form of a flat member 1402 and a second anchoring means 1404, in the form of an L-shaped member 1404. An inner screw 1406 is arranged to pass through respective passages in the flat member 1402 and L-shaped member 1404. A first end 1408 of the inner screw 1406, which passes through a passage in the flat member 1402, has a head 1410, the head 1410 prevents the inner screw 1406 from passing through the passage in the flat member 1402. A second end 1412 of the inner screw 1406, which passes through a passage in a first face 1414 of the L-shaped member 1404 has a screw thread which is capable of being screwed into a corresponding thread on a first gear 1416. The L-shaped member 1404, on a second face 1416, has a second passage through which a shaft 1418 passes through. On one end of the shaft 1418 is a second gear 1420 and on the other end of the shaft is a hexagonal drive 1422. The first gear 1416 and second gear 1420 are engageable such that rotation of one gear rotates the other.
In this example, the gears 1316, 1320, 1416, 1420 are advantageously shown at substantially 90 degrees, but other angles are possible, according to requirements, without detracting from the main purpose, which is to provide quick and easy tightening of the clamping means. For example, a particularly preferred method of rotating the hexagonal drive 1322, 1422 is by an electric drill or screwdriver. However, the fact that the hexagonal drive is presented at 90 degrees to the clamping means and is offset means a regular spanner or socket could also be used. Prior art clamping means are known which simply comprise a bolt and nut and provide difficult access by standard tools when fitting kitchen worktops. In particular, access to the nut typically only allows use of a spanner and only approximately a quarter of a turn is possible. The clamping means disclosed herein allows full rotation and use of electric tools, to vastly increase the speed at which worktops can be installed.
The gears 1316, 1320, 1416, 1420 are shown as bevel gears, however, any gears suitable to change the angle of rotation can be used.
Referring now to
A plurality of clips 1104 extend from the sink 1102. The clips 1104 include a sprung steel portion 1106. When the sink 1102 is inserted into the board 1100, the clips 1104 deform as they pass through hole and, when they reach the far side of the board 1100, spring out to grip onto the bottom side of the board 1100.
In this manner, sinks, stove tops and other features which require to be installed into a composite stone worktop can be installed quickly and efficiently.
Referring now to
The worktop 1502 contains recesses 1504 at either end. A backing board 1506, shown in dashed lines in this case, provides additional support for the worktop 1502 as described above.
Shown in
In this manner, a waterfall assembly 1500 can be easily constructed by slotting the protrusion's 1510 of two waterfall ends 1508 into the recesses 1504 of the worktop 1502. Adhesive can be applied to the mating surfaces 1512 of the protrusions and recesses to ensure that the waterfall ends and worktop are securely fixed. However, the structure is designed to be supported by the depth of the protrusions and recesses.
Modifications and improvements may be made without departing from the scope of the present invention.
Claims
1.-42. (canceled)
43. A method of manufacturing a composite stone board including: providing a mixture of stone particles and a binder, providing as mould, wherein the mixture is deposited on the mould and subsequently hardened to provide the composite stone board, wherein the mould includes recesses such that the composite stone hoard has corresponding projections which provide support to the composite stone board.
44. A method as claimed in claim 43, wherein the mould is a hacking hoard, the composite stone board, therefore, being formed with an integral backing board.
45. A method as claimed, in claim 43, wherein the method further comprises removing the composite stone board from the mould and placing the composite stone board on a hacking board.
46. A method as claimed in claim 43, wherein the method enables the provision of edges on the composite stone hoard capable of hiding a backing board.
47. A method as claims in claim 46, wherein the mould includes edges on the composite stone board.
48. A composite stone board, created from a mixture of stone particles and a hinder, having integrally formed projections on one surface.
49. A composite stone board as claimed in claim 48, wherein the composite stone board includes integrally formed edges capable of hiding a backing board.
50. A composite stone worktop including a composite stone board as claimed in claim 48, having a hacking board formed therein.
51. A composite stone worktop as claimed in claim 50, wherein the backing board is integrally formed with the composite stone worktop.
52. A composite stone worktop as claimed in claim 50, wherein the backing board is made of plastic, wood, metal, carbon fibre, or a combination of these materials.
53. A composite stone worktop as claimed in claim 50, wherein the backing board has a plurality of recesses corresponding to the projections on the composite stone board.
54. A composite stone worktop including a composite stone board created from a mixture of stone particles and a binder, having integrally formed projections on one surface, having a backing board formed therein, wherein the composite stone hoard is manufactured according to claim 43.
Type: Application
Filed: Jul 4, 2013
Publication Date: Aug 6, 2015
Applicant: Lode Enterprises Pty Ltd (Melbourne, Victoria)
Inventor: Atis Eriks Lode (Melbourne)
Application Number: 14/412,103